U.S. patent number 7,823,280 [Application Number 12/270,618] was granted by the patent office on 2010-11-02 for method for manufacturing connector of electronic clutch for compressor.
This patent grant is currently assigned to Halla Climate Control Corp.. Invention is credited to Suk-Jae Chung, Sung-Taeg Oh, Dae-Yong Park, Hwa-Yeop Shin.
United States Patent |
7,823,280 |
Chung , et al. |
November 2, 2010 |
Method for manufacturing connector of electronic clutch for
compressor
Abstract
The present invention relates to a connector of an
electromagnetic clutch for a compressor and a manufacturing method
thereof. The method includes the steps of arranging a leading end
of a lead wire 62 or 72 of at least one discharge device 60 or
remaining magnetic field removing device 70, which configures a
surge absorbing circuit, to a terminal 50 installed in a connector
30 configuring a field coil assembly and having a coupling slot 56
formed in one side thereof; plastically deforming at least one slot
bridge 57 to fix the lead wire 62 or 72 to the coupling slot 56;
and making the connector 30 in a state where the terminal 50 is
fixed to an assembly of at least the discharge device 60 or
remaining magnetic field removing device 70 by injection
molding.
Inventors: |
Chung; Suk-Jae (Daejeon,
KR), Oh; Sung-Taeg (Daejeon, KR), Park;
Dae-Yong (Daejeon, KR), Shin; Hwa-Yeop (Daejeon,
KR) |
Assignee: |
Halla Climate Control Corp.
(Daejeon, KR)
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Family
ID: |
40640457 |
Appl.
No.: |
12/270,618 |
Filed: |
November 13, 2008 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20090126185 A1 |
May 21, 2009 |
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Foreign Application Priority Data
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Nov 16, 2007 [KR] |
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10-2007-0117073 |
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Current U.S.
Class: |
29/856; 264/478;
264/465; 29/883; 264/453; 439/620.33; 264/37.33; 29/858;
439/620.13; 29/855; 29/854; 439/620.01 |
Current CPC
Class: |
H01R
13/112 (20130101); H01R 31/06 (20130101); F16D
27/00 (20130101); H01R 13/7197 (20130101); H01R
4/183 (20130101); H01R 13/113 (20130101); H01R
13/405 (20130101); Y10T 29/4922 (20150115); F16D
2250/00 (20130101); Y10T 29/49071 (20150115); Y10T
29/49176 (20150115); Y10T 29/49169 (20150115); Y10T
29/49171 (20150115); Y10T 29/49172 (20150115) |
Current International
Class: |
H01R
43/00 (20060101); H05K 13/00 (20060101) |
Field of
Search: |
;29/854,855,856,857,858,883 ;264/453,478,37.37,465,37.33
;439/620-622,620.01,620.04,620.08,620.13,620.26,620.33 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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1900547 |
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Jan 2007 |
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CN |
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10-318290 |
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Dec 1998 |
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JP |
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10-318290 |
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Dec 1998 |
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JP |
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10318290 |
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Dec 1998 |
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JP |
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WO-2004/067982 |
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Aug 2004 |
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WO |
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Primary Examiner: Banks; Derris H
Assistant Examiner: Carley; Jeffrey
Attorney, Agent or Firm: Birch, Stewart, Kolasch &
Birch, LLP
Claims
What is claimed is:
1. A method for manufacturing a connector of an electromagnetic
clutch for a compressor, in which the electromagnetic clutch
includes a field coil assembly being supplied with external power
through the connector provided at one side thereof to generate an
attracting magnetic flux by a coil wound therein, the method
comprising the steps of: arranging a leading end of a lead wire of
at least one discharge device or remaining magnetic field removing
device configuring a surge absorbing circuit to a coupling slot
formed in one side of a terminal provided in the connector;
plastically deforming at least one slot bridge to fix the lead wire
to the coupling slot; and making the connector in a state where the
terminal is fixed to an assembly of at least the discharge device
or remaining magnetic field removing device by injection molding,
wherein at least one injection groove is formed on an outer surface
of the connector to prevent the surge absorbing circuit from waving
during the injection molding.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnetic clutch for a
compressor, and more particularly, to a method for manufacturing a
connector of a field coil assembly provided in an electromagnetic
clutch for a compressor.
2. Description of the Related Art
Generally, an electromagnetic clutch for a compressor is an
electric device, wherein a magnetic field is formed by
electromagnetic induction of a wound coil when power is supplied
thereto and a resultant magnetic force causes a hub disc at a
driving shaft of a compressor to be attracted toward a frictional
surface of a pulley and to be dynamically connected thereto,
whereby driving force of the pulley rotated by an engine is
transferred to the hub disc of the driving shaft of the
compressor.
That is, the electromagnetic clutch for a compressor serves to
control the operation of a cooling system of an air conditioner by
regulating power of the compressor according to whether or not
power is applied to the coil.
FIG. 1 is an exploded perspective view showing a coil assembly of a
conventional electromagnetic clutch for a compressor, and FIG. 2 is
a plan view showing a major portion of a connector of the
conventional electromagnetic clutch for a compressor.
According to the figures, the electromagnetic clutch for a
compressor includes a pulley (not shown) connected to a crank shaft
of an engine by means of a driving belt (not shown) and having a
frictional surface at a side thereof.
Also, the electromagnetic clutch for a compressor is provided with
a field coil assembly 1, so that it is contained in the pulley and
supported by a housing (not shown) and also generates an attracting
magnetic flux by applied power. The attracting magnetic flux
generated by the field coil assembly 1 makes a disc (not shown) be
coupled to the frictional surface of the pulley, thereby
transferring the power of the engine to a driving shaft of the
compressor.
An electromagnetic coil is wound in the shape of a ring inside of a
body 2 that defines a framework of the field coil assembly 1. A
protrusion 3 is provided at one side of the body 2, and a connector
mount 5 is coupled to an upper surface of the protrusion 3.
Terminal insertion grooves 7 are formed on the connector mount 5,
and are portions into which terminals 15 of a connector 10, which
will be described later, are inserted.
The connector 10 is coupled to the body 2. The connector 10
receives power from the outside and transfers it into the body 2
through the terminals 15, thereby causing the field coil assembly 1
to form a magnetic field.
An external appearance and framework of the connector 10 is defined
by a housing 11. The housing 11 is made of an insulating material
such as synthetic resin. A coupling portion 13 for coupling with a
counterpart is formed at one side of the housing 11, and the
terminals 15 to be coupled and electrically connected to the
connector mount 5 is provided at the other side of the housing
11.
At this time, as shown in FIG. 2, electric parts such as a diode D
and a resistor R are installed inside of the housing 11. The diode
D and the resistor R form a surge absorbing circuit in the
connector 10, and are electrically connected to the terminals
15.
A manufacturing process of the connector 10 will be described.
First, the terminals 15 are injection molded such that the
terminals 15 may be provided integrally with the housing 11. That
is, the housing 11 is injection molded while the terminals 15 are
inserted in a mold assembly, so that the housing 11 is manufactured
as being fixed to the terminals 15.
In such a state, the diode D and the resistor R are inserted into
the housing 11. At this time, the diode D and the resistor R are
assembled to be connected to one ends of the terminals 15. Then, a
thermosetting resin such as epoxy resin E is injected into the
housing 11 to fix the diode D and the resistor R.
That is, after injection molding is conducted with the terminals 15
inserted into the housing 11, the diode D and the resistor R are
assembled in the housing 11.
However, since an additional process for injecting the epoxy resin
E is separately required in a process of assembling the diode D and
the resistor R, there is a problem in that the number of processes
and production costs for the connector 10 is increased.
In particular, if the diode D and the resistor R are fixed using
the epoxy resin E, a time is required for solidifying the epoxy
resin E, and thus, there is a problem in that the entire production
time for the connector 10 is extended.
In addition, Japanese Laid-open Patent Publication No. 1998-318290
discloses that a surge absorbing device is accommodated in a
connector of an electromagnetic clutch. However, before a connector
of a power source is coupled to the connector of the clutch, the
surge absorbing device or a coupling portion between the surge
absorbing device and the terminals are exposed to the outside,
which may cause a problem such as bad connection between the
terminals and the surge absorbing device due to insertion of
foreign substance.
SUMMARY OF THE INVENTION
The present invention is conceived to solve the aforementioned
problems in the related art. An object of the present invention is
to allow electric parts configuring a surge absorbing circuit and
terminals connected thereto to be assembled in a connector through
injection molding.
The present invention provides a method for manufacturing a
connector of a field coil assembly, in which the field coil
assembly is supplied with external power through the connector
provided at one side thereof to generate an attracting magnetic
flux by a coil wound therein, the method comprising the steps of:
arranging a leading end of a lead wire of at least one discharge
device or remaining magnetic field removing device configuring a
surge absorbing circuit to a coupling slot formed in one side of a
terminal provided in the connector; plastically deforming at least
one slot bridge to fix the lead wire to the coupling slot; and
making the connector in a state where the terminal is fixed to an
assembly of at least the discharge device or remaining magnetic
field removing device by injection molding.
At least one injection groove may be formed on an outer surface of
the connector to prevent the surge absorbing circuit from waving
during the injection molding.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the present invention will become
apparent from the following description of a preferred embodiment
given in conjunction with the accompanying drawings, in which:
FIG. 1 is an exploded perspective view showing a field coil
assembly of a conventional electromagnetic clutch for a
compressor;
FIG. 2 is a plan view showing a major portion of a connector of the
conventional electromagnetic clutch for a compressor;
FIG. 3 is a perspective view showing a connector manufactured
according to a method for manufacturing a connector of an
electromagnetic clutch for a compressor according to the present
invention;
FIG. 4 is an opened-up perspective view showing the interior of the
connector of FIG. 3;
FIG. 5 is a perspective view showing that lead wires of electric
parts installed in the connector according to the embodiment of the
present invention is arranged in coupling slots of terminals;
FIG. 6 is a perspective view showing that a slot bridge of the
terminals are plastically deformed to fix the lead wires of the
electric parts of FIG. 5; and
FIG. 7 is a flowchart subsequently illustrating a process of
manufacturing a connector of an electromagnetic clutch for a
compressor according to an embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinafter, a preferred embodiment of a method for manufacturing a
connector of an electromagnetic clutch for a compressor according
to the present invention will be described in detail with reference
to the accompanying drawings.
FIG. 3 is a perspective view showing a connector manufactured
according to the method for manufacturing a connector of an
electromagnetic clutch for a compressor according to the present
invention, FIG. 4 is an opened-up perspective view showing the
interior of the connector of FIG. 3, and FIGS. 5 and 6 are
perspective views showing that lead wires of electric parts
installed in the connector according to the embodiment of the
present invention is arranged in coupling slots of terminals and
that a slot bridge of the terminals are plastically deformed to fix
the lead wires of the electric parts, respectively. Hereinafter, a
body and other components of a field coil assembly refer to the
related art, and the following explanation will be focused on the
connector manufacturing method.
According to the figures, an external appearance and framework of a
connector 30 is defined by a housing 31. The housing 31 is made of
an insulating material such as synthetic resin by injection
molding.
An injection groove 35 is concavely formed on an outer surface of
the housing 31. The injection groove 35 is to prevent electric
parts 60 and 70, which are assembled in the housing 31 during an
injection process thereof as explained later, from waving. More
specifically, an injection mold is provided with a core (not shown)
for forming the injection groove 35, so that the positions of the
electric parts 60 and 70 may be fixed by means of the core. The
injection groove 35 is preferably positioned between a plurality of
electric parts 60 and 70.
At this time, although FIG. 3 shows only one injection groove 35,
the present invention is not limited thereto. A plurality of
injection grooves may be formed on upper and lower surfaces of the
housing 31. That is, injection grooves 35 may be formed
corresponding to the electric parts 60 and 70 in number and
position. Of course, no injection groove 35 may be formed in the
housing 31.
Fixing protrusions 37 are provided on one side of the housing 31.
The fixing protrusions 37 are to fix the connector 30 to a body 2
of a field coil assembly 1. To this end, the fixing protrusions 37
are provided in a pair at a rear end of the housing 31 as shown in
the figures.
As shown in FIG. 5, terminals 50 are provided inside of the housing
31. The terminals 50 are to transmit external power to a coil wound
in the field coil assembly 1, and are made of a metal material with
good electric conductivity. The terminals 50 come into contact with
terminals of an opposite connector (not shown) connected to the
external power and is electrically connected thereto, thereby
transmitting the external power to the field coil assembly 1. To
this end, the terminals 50 should be installed such that at least
portion thereof is exposed to the outside of the housing 31. In
this embodiment, the terminals 50 are provided in a pair in the
housing 31.
A framework of the terminal 50 is defined by a bar-shaped body 51,
and both ends 52 and 55 of the body 51 are respectively connected
to an opposite connector (not shown) and a connector mount 5 of the
field coil assembly 1.
At this time, the body 51 of the terminal 50 is formed with a
coupling slot 56. The coupling slot 56 is formed by partially
cutting the body 51, and is a portion to which a lead wire 62 or 72
of the electric part 60 or 70, which will be described later, is
coupled. In this embodiment, the coupling slot 56 is formed to pass
through a part of the body 51, but not limited thereto. That is, a
part of the body 51 corresponding to one side of the coupling slot
56 may be cut such that one end of the coupling slot 56
communicates with the outside.
A slot bridge 57 is provided at one side of the coupling slot 56.
The slot bridge 57 is formed while the coupling slot 56 is formed
by cutting, and is provided across the coupling slot 56. That is, a
predetermined space is formed between the coupling slot 56 and the
slot bridge 57 such that the lead wire 62 or 72 of the electric
part 60 or 70 may pass therethrough.
At this time, there may be provided a plurality of coupling slots
56 and slot bridges 57. That is, though there are provided only one
coupling slot 56 and only one slot bridge 57 in this embodiment,
the present invention is not limited thereto. More specifically, a
plurality of coupling slots 56 and slot bridges 57 may be formed in
the body 51 of the terminal 50 along a direction in which the lead
wire 62 or 72 of the electric part 60 or 70 is arranged. In this
case, the lead wire 62 or 72 of the electric part 60 or 70 is fixed
to the plurality of coupling slots 56, so that the terminal 50 may
be more stably coupled to the electric part 60 or 70.
Alternatively, slot bridges 57 may be provided in a pair to face
each other in the body 51 of the terminal, and the lead wire 62 or
72 of the electric part 60 or 70 may be bent such that the slot
bridges 57 approach each other while the lead wire 62 or 72 is
inserted between the pair of slot bridges 57, thereby making the
lead wire 62 or 72 be compressed between the slot bridges 57.
The electric parts 60 and 70 are electrically connected to the
terminals 50. The electric parts 60 and 70 are to configure a surge
absorbing circuit to the connector 30, and are composed of a
discharge device 60 and a remaining magnetic field removing device
70. In this embodiment, the discharge device 60 and the remaining
magnetic field removing device 70 respectively comprise a diode 60
and a resistor 70, but the present invention is not limited
thereto. Also, the surge absorbing circuit may be composed of only
a diode 60. The diode 60 and the resistor 70 are electrically
connected to the terminals 50 provided in a pair.
As shown in FIGS. 5 and 6, the diode 60 is provided with a lead
wire 62. The lead wire 62 is to electrically connect to one of the
terminals 50, and is formed to extend in one side. More
specifically, a leading end 65 of the lead wire 62 is fixed to the
coupling slot 56 by means of the slot bridge 57 of the terminal 50,
so that the diode 60 is electrically connected to the terminal
50.
The resistor 70 is also provided with a lead wire 72, like the
diode 60. The lead wire 72 is to electrically connect to the other
of the terminals 50, and is formed to extend in one side. In
specifically, a leading end 75 of the lead wire 72 is fixed to the
coupling slot 56 by means of the slot bridge 57 of the terminal 50,
so that the resistor 70 is electrically connected to the terminal
50.
At this time, the coupling between the terminal 50 and the electric
part 60 or 70 is not limited to the configuration of the coupling
slot 56 and the slot bridge 57. For example, the lead wire 62 or 72
of the electric part 60 or 70 may pass through a coupling hole (not
shown), which is bored through a part of the terminal 50, and then,
may be bent such that the terminal 50 is electrically connected to
the electric part 60 or 70.
Alternatively, the lead wire 62 or 72 of the electric part 60 or 70
may also be fixed to the terminal 50 by soldering or insulating
tape.
Hereinafter, a method for manufacturing a connector of an
electromagnetic clutch for a compressor according to the present
invention will be described.
First, before the housing 31 is injection molded, the terminals 50
are coupled with the electric parts 60 and 70 that configure a
surge absorbing circuit. That is, the terminals 50 are electrically
connected to the surge absorbing circuit.
More specifically, the lead wires 62 and 72 of the diode 60 and the
resistor 70 are respectively arranged to the coupling slots 56 of
the terminals 50. This configuration is shown in FIG. 5. In a case
where a plurality of coupling slots 56 are formed, each of the lead
wires 62 and 72 is arranged across a plurality of the coupling
slots 56 (S100).
In this state, the slot bridge 57 of the terminal 50 is pressed
toward the lead wire 62 or 72 to be plastically deformed. At this
time, the process of deforming the slot bridge 57 may be conducted
using a press die. If the slot bridge 57 is pressed and plastically
deformed as mentioned above, the lead wire 62 or 72 is compressed
between the slot bridge 57 and the coupling slot 56, thereby being
firmly fixed (SI 10). This state is shown in FIG. 6.
As explained above, the lead wires 62 and 72 may also be fixed to
the terminals 50 by soldering or the like.
Next, the terminals 50 and the assembly of the diode 60 and the
resistor 70 are positioned in an injection mold, and then, the
housing 31 is made by injection molding. More specifically, the
terminals 50 and the assembly of the electric parts 60 and 70 that
configure the surge absorbing circuit are positioned in a cavity of
a mold assembly used for forming the housing 31, and then, a molten
resin is injected thereinto to make the connector 30 (S120).
At this time, since the injection groove 35 is formed in the
housing 31, the diode 60 and the resistor 70 may be fixed at
accurate positions in the housing 31 while the resin is injected
and flows in the cavity.
In this state, the terminals 50 and the assembly of the diode 60
and the resistor 70 are fixed together with the housing 31, thereby
being integrally assembled. Thus, there is no need of a separate
process for injecting a thermosetting resin in order to fix the
diode 60 and the resistor 70 in the housing 31.
In addition, in a process where the connector 30 is made by
injection molding, the coupling portions between the terminals 50
and the electric parts 60 and 70 are naturally shielded, so that
foreign substance can be prevented from being introduced between
the terminals 50 and the electric parts 60 and 70.
Finally, the connector 30 manufactured as above is connected to the
connector mount 5 provided in the body 2 of the field coil assembly
1. That is, the leading ends of the terminals 50 are inserted into
terminal insertion grooves 7 formed in the connector mount 5, so
that the connector 30 is electrically connected to the body 2 of
the field coil assembly 1 (S130).
The scope of the present invention is not limited to the embodiment
described and illustrated above but is defined by the appended
claims. It will be apparent that those skilled in the art can make
various modifications and changes thereto within the scope of the
invention defined by the claims.
In the present invention, a surge absorbing circuit is assembled in
a connector, which configures an electromagnetic clutch for a
compressor, by injection molding. Accordingly, there is no need of
a separate process for injecting a thermosetting resin so as to fix
the surge absorbing circuit in the connector, thereby decreasing
the number of processes for assembling a connector and also
reducing a production cost.
Also, during the process of manufacturing a connector, there is no
need of a time required for solidifying a thermosetting resin,
thereby decreasing a time required for manufacturing a
connector.
In addition, since a space between the terminals and the surge
absorbing circuit installed to the connector is naturally shielded
during the injection molding, thereby preventing foreign substance
from being introduced, the improved operation reliability of the
connector can also be expected.
* * * * *